2002 TOYOTA AVENSIS check engine light

A77437
Cylinder Head
Cylinder Block
Seal Packing
Cylinder
Head Gasket
2.5 to 3 mm
12.5 to 1.5 mm
A7741012
3
4
10 9
85
67
A00976A77411
90
Engine
Front Paint Mark
14±260
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(a)Apply a continuous bead (Diameter 2.5 to 3 mm (0.098 to 0.118 in.)) of seal packing as shown in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from contact surface.

Install the cylinder head within 3 minutes after apply-
ing seal packing.

After installing the cylinder head, cylinder head bolts
must be tightened within 15 minutes.

Do not start the engine within 2 hours after installing.
(b)Apply a light coat of engine oil on the threads of the cylin- der head bolts.
(c)Install bolts and plate washers to the cylinder head.
NOTICE:
Do not drop the washers into the cylinder head.
(d)Using several steps, install and tighten the 10 cylinder head bolts and plate washers with a 10 mm bi±hexagon
wrench uniformly, in the sequence shown in the illustra-
tion.
Torque: 79 N
m (806 kgf
cm, 58 ft
lbf)
(e)Mark the front side of the cylinder head set bolts with paint.
(f)Retighten the cylinder head set bolts by 90  in the same
sequence as a step (d).
(g)Check that each paint mark is now at a 90  angle to the
front.
64.INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a)Install a light coat of the engine oil to the new O±ring and install \
it to the oil control valve.
(b)Install the oil control valve with the bolt. Torque: 9.0 N
m (92 kgf
cm,79 in.
lbf)
65.INSTALL CAMSHAFT (See page 14±240)
66.INSTALL NO.2 CAMSHAFT (See page 14±240)

A61189
10
11
12
13 14
15 16
17
18
2
1
4
5 6
3
7 8
9
(A) (A)
(A)
(A) (A)
(A)
(A)
(B) (B) (B) (B) (B) (B) (B)
(B)
(B)
(B) (A)
A61190
90
 90

9090
 90

90
Front Paint Mark
90
A09683
TDC Mark
Dot Mark
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±337
AVENSIS REPAIR MANUAL (RM1018E)
70. INSTALL CYLINDER HEAD SUB±ASSY
HINT:

The cylinder head bolts are tightened in 4 successive
steps (steps (c), (e), (f) and (g)).

If the cylinder head bolt is broken or deformed, replace it
with a new bolt.
(a) Apply a light coat of engine oil on the threads of the cylin-
der head bolts and the plate washers.
(b) Install the plate washer to the cylinder head bolt.
(c) Using several steps, install and tighten the 18 cylinder head bolts uniformly in the sequence shown in the illustra-
tion.
Torque: 45 N
m (459 kgf
cm, 33 ft
lbf)
HINT:
See the table below for the bolt length.
Bolt TypeBolt Length
(A)160mm (6.30 in.)
(B)104mm (4.09 in.)
If the cylinder head bolt does not meet the torque specification,
replace the cylinder head bolt with a new bolt.
(d) Mark the front of the cylinder head bolt with paint.
(e) Retighten the cylinder head bolts by 90  in the same se-
quence as step (c).
(f) Retighten the cylinder head bolts by additional 90  in the
same sequence as step (c).
(g) Retighten the cylinder head bolts by one more additional 90 in the same sequence as step (c).
(h) Check that each painted mark is now at the intake man- ifold side.
71. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Using the crankshaft pulley bolt, turn the crankshaft to set the dot mark of the crankshaft timing pulley at the position
of 90  BTDC.
NOTICE:
If the timing belt is disengaged, having the crankshaft tim-
ing pulley at wrong angle can cause the piston head and
valve head to come into contact with each other.
72.INSTALL CAMSHAFT (See page 14±318)
73.INSTALL NO.2 CAMSHAFT (See page 14±318)
74.REMOVE CAMSHAFT OIL SEAL (See page 14±318)
75.INSTALL CAMSHAFT OIL SEAL (See page 14±318) SST 09223±46011

A62816
84 2 59
7 3 1 6 10
A62823
Paint Mark
90

Front
A62150
Camshaft No. 2
Camshaft
A62825
62 4 8
51 3 7 11
10
9
A10079
14±88
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
52. INSTALL CYLINDER HEAD SUB±ASSY
HINT:
The cylinder head bolts are tightened in 2 successive steps.
(a) Apply a light coat of engine oil on the threads of the cylin-
der head bolts.
(b) Using several steps, install and tighten the 10 cylinder
head bolts and plate washers with a 10 mm hexagon
wrench uniformly in the sequence shown in the illustra-
tion.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
(c) Mark the front of the cylinder head bolt with paint.
(d) Retighten the cylinder head bolts 90
in the same se-
quence as step (b).
(e) Check that the paint mark of each bolt is at 90
angle to
the front.
53. INSTALL CAMSHAFT
(a) Apply a light coat of engine oil on the camshaft journals.
(b) Place the 2 camshafts on the cylinder head as shown in
the illustration.
(c) Examine the front marks and numbers and tighten the
bolts in the sequence shown in the illustration.
Torque:
23 N
m (235 kgf
cm, 17 ft
lbf) for Bearing cap No. 1
13 N
m (133 kgf
cm, 10 ft
lbf) for Bearing cap No. 3
54. INSTALL CHAIN SUB±ASSY
(a) Set No. 1 cylinder to TDC/compression.
(1) Turn the camshafts using a wrench to align the tim-
ing marks of the 2 camshaft timing sprockets.

A65677
A
A
AA
A
A
AAA B
B
B
A62177
Raise
Push
Hook
Pin
A62178
Push
A76692
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
14±91
AVENSIS REPAIR MANUAL (RM1018E)
(c) Install the timing chain cover with the 11 bolts and nut.
Torque:
13 N
m (133 kgf
cm, 10 ft
lbf) for A
19 N
m (194 kgf
cm, 14 ft
lbf) for B
(d) Using a torx wrench socket (E8), install the stud bolt.
Torque: 9.5 N
m (97 kgf
cm, 84 in.
lbf)
60. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Check that the O±ring is clean, and set the hook as shown
in the illustration.
(b) Apply engine oil to the chain tensioner and install it with
the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
NOTICE:
If the hook released the plunger during installation, re±
hook the plunger by the hook to fix it.
61. INSTALL CRANKSHAFT POSITION SENSOR
(a) Apply a light coat of the engine oil to the O±ring on the
crankshaft position sensor.
(b) Install the crankshaft position sensor with the 2 bolts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)

140D1±02
CG
TCA51075
A52004
±
ENGINE MECHANICAL ENGINE(1AZ±FE)
14±101
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE(1AZ±FE)
INSPECTION
1.INSPECT COOLANT (See page 16±13)
2.INSPECT ENGINE OIL (See page 17±6)
3. INSPECT BATTERY
Standard specific gravity: 1.25 to 1.29 at 20 C (68 F)
4. INSPECT AIR CLEANER FILTER ELEMENT SUB±ASSY
5.INSPECT SPARK PLUG (See page 18±9)
6. INSPECT V±RIBBED BELT
7. INSPECT IGNITION TIMING
(a) Warm up engine.
(b) When using hand±held tester:(1) Connect the hand±held tester to the DLC3.
(2) Enter DATA LIST MODE on the hand±held tester.
Ignition timing: 8 to 12  BTDC
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester:
(1) Using SST, connect terminals 13 (TC) and 4 (CG)of DLC3.
SST 09843±18040
NOTICE:

Make sure of the terminal numbers before connecting
them. Connection with a wrong terminal can damage
the engine.

Turn OFF all electrical systems before connecting the
terminals.

Operate the inspection after the cooling fan motor is
turned OFF.
(2) Remove the cylinder head cover No.2.
(3) Pull out the wire harness as shown in the illustration.
Connect the clip of the timing light to the engine.
NOTICE:

Use a timing light which detects the first signal.

After checking, be sure to wrap the wire harness with
tape.
(4) Inspect ignition timing at idle.
Ignition timing: 8 to 12  BTDC
NOTICE:
When checking the ignition timing, shift the transmission
to the neutral position.
HINT:
Run the engine at 1,000 to 1,300 rpm for 5 seconds, check that
the engine rpm returns to the idle speed.

TA C
A52006
A13304
14±102
± ENGINE MECHANICALENGINE (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(5) Disconnect terminals 13 (TC) and 4 (CG) of DLC3.
(6) Inspect ignition timing at idle.
Ignition timing: 5 to 15 BTDC
(7) Confirm that ignition timing to go advanced angle
side when the engine rpm is increased.
(8) Remove the timing light.
8. INSPECT ENGINE IDLE SPEED
(a) Warm up engine.
(b) When using hand±held tester:
(1) Connect the hand±held tester to the DLC3.
Idle speed: 650 to 750 rpm
NOTICE:

Check the idle speed with the cooling fan OFF.

Switch off all accessories and air conditioning before
connecting the test prove to the terminal.
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester.
(1) Using SST, connect the tachometer test prove to
terminal 9 (TAC) of DLC3.
SST 09843±18040
(2) Check the idle speed.
Idle speed: 650 to 750 rpm
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Disconnect the injector connectors.
(c) Remove the ignition coil.
(d) Remove the spark plugs.
(e) Inspect cylinder compression pressure.
SST 09992±00500
(1) Insert a compression gauge into the spark plug
hole.
(2) Fully open the throttle.

141CP±01
CG
TCA51075
A79034
±
ENGINE MECHANICAL ENGINE(1AZ±FSE)
14±181
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE(1AZ±FSE)
INSPECTION
1.INSPECT COOLANT (See page 16±25)
2.INSPECT ENGINE OIL(See page 17±13)
3.INSPECT BATTERY
Standard specific gravity: 1.25 to 1.29 at 20 C (68 F)
4.INSPECT AIR CLEANER FILTER ELEMENT SUB±ASSY
5.INSPECT SPARK PLUG (See page 18±14)
6.INSPECT V±RIBBED BELT
7.INSPECT IGNITION TIMING
(a)Warm up engine.
(b)When using hand±held tester:(1)Connect the hand±held tester to the DLC3.
(2)Enter DATA LIST MODE on the hand±held tester.
Ignition timing: 8 to 12  BTDC
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester:
(1) Using SST, connect terminals 13 (TC) and 4 (CG)of DLC3.
SST 09843±18040, 09843±18020
NOTICE:

Make sure of the terminal numbers before connecting
them. Connection with a wrong terminal can damage
the engine.

Turn OFF all electrical systems before connecting the
terminals.

Operate the inspection after the cooling fan motor is
turned OFF
(2) Remove the cylinder head cover No.2.
(3) Pull out the wire harness as shown in the illustration.
Connect the clip of the timing light to the engine.
NOTICE:

Use a timing light which detects the first signal.

After checking, be sure to wrap the wire harness with
tape.
(4) Inspect ignition timing at idle.
Ignition timing: 8 to 12  BTDC
NOTICE:
When checking the ignition timing, shift the transmission
to the neutral position.
HINT:
Run the engine at 1,000 to 1,300 rpm for 5 seconds, check that
the engine rpm returns to the idle speed. (5) Disconnect terminals 13 (TC) and 4 (CG) of DLC3.

TA C
A52006
14±182
± ENGINE MECHANICALENGINE (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(6) Inspect ignition timing at idle.
Ignition timing: 5 to 23 BTDC
(7) Confirm that ignition timing to go advanced angle
side when the engine rpm is increased.
(8) Remove the timing light.
8. INSPECT ENGINE IDLE SPEED
(a) Warm up engine.
(b) When using hand±held tester:
(1) Connect the hand±held tester to the DLC3.
Idle speed: 625 to 725 rpm
NOTICE:

Check the idle speed with the cooling fan OFF.

Switch off all accessories and air conditioning before
connecting the test prove to the terminal.
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester:
(1) Using SST, connect the tachometer test prove to
terminal 9 (TAC) of DLC3.
SST 09843±18040
(2) Check the idle speed.
Idle speed: 625 to 725 rpm
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Disconnect the injector connectors.
(c) Remove the ignition coil.
(d) Remove the spark plugs.